TUBULAR KING PILE FOUNDATION- Robust and Resilient Foundation System with High Cost Efficiency -Vol.2 Construction

Table of Contents
Chapter 1Introduction ············································································································ 1

Chapter2

Standard Procedure ································································································· 2
2-1 Overall Procedure ······························································································· 2
2-2 Initial Piling ········································································································ 3

Chapter3Work Layout ············································································································ 5
3-1 Standard Operation (Above Ground) ··································································· 5
3-2 Standard Operation (Above Water) ····································································· 6
3-3 GRB Operation (Non-staging Method) ································································· 7Chapter4Machine Specification ······························································································ 84-1 Machine Specification (F301-G1000) ··································································· 84-2 Machine Specification (F401-G1200) ································································· 12

Chapter 1Introduction

The purpose of this document is to provide practical guidelines for the construction of the Tubular King
Pile Foundation.
The intended audience for this document is engineers and construction specialists involved in the design,construction, and contracting of foundation elements for infrastructures.
The press-in piling method is commonly used worldwide because of its very quiet operation, ultralow
vibration, and flexibility of sizes to suit different wall properties and subsoil conditions.
The main attributes of the Tubular King Pile Foundation are efficiency of physical wall properties andversatility. The Tubular King Pile Foundation comprises steel tubular piles as the primary foundation
element and incorporating additional upper wall elements on top of the steel tubular piles. The
efficiencies of physical foundation properties can be optimized in view of the flexibility of pile size andthe spacing of tubular piles for the ground conditions and the form of the loading. The Tubular King Pile
Foundation is installed by the press-in method and pile penetration force is monitored and recorded
throughout the piling operation. This thorough monitoring and recording system alleviates concerns ofquality control, as well as providing a comprehensive quality control method for a performance-based
contracting process.
This document provides a description of construction equipment and procedures of the Tubular KingPile Foundation.

1

Chapter 2Standard Procedure

2-1 Overall Procedure

Skiplock Attachments

Tubular Pile

Tubular Pile
Gyro Piler

Tubular Pile2

2-2 Initial Piling

Saddle & Clamps
Reaction Piles

Reaction Stand

1.Installing of sheet piles as reaction piles
Note: The sheet pile length for initial reaction
force is determined by site conditions

3.Fixing of Saddle & Clamps to Reaction Stand

2.Fixing of Reaction Stand to reaction piles
by bolts and welds(F301-G1000)
Saddle & Clamps:
4.25 ton (Ø 600mm)
4.90 ton (Ø 800mm)
5.45 ton (Ø 1000mm)(F401-G1200)
Saddle & Clamps:
10.25 ton (Ø 800mm)
11.00 ton (Ø 1000mm)
11.00 ton (Ø 1200mm)

Chuck
Mast

4.Fixing of Mast to Saddle(F301-G1000)
Mast:4.20ton(F401-G1200)
Mast:8.80ton

Tubular Pile

7.Installing of tubular pile

5.Fixing of Chuck to Mast
(F301-G1000)(F401-G1200)
Chuck:
Chuck:
7.55 ton (Ø 600mm)
12.80 ton (Ø 800mm)
7.50 ton (Ø 800mm)
12.80 ton (Ø 1000mm)
7.55 ton (Ø 1000mm) 13.20 ton (Ø 1200mm)6.Completion of assembly of Gyro Piler(F301-G1000)(F401-G1200)
Total mass:
Total Mass:
16.00 ton (Ø 600mm)
31.85 ton (Ø 800mm)
16.60 ton (Ø 800mm)
32.60 ton (Ø 1000mm)
17.20 ton (Ø 1000mm)
33.60 ton (Ø 1200mm)

Skiplock Attachment

Driving Attachment

8.Pitching of Driving Attachment
onto top of pile and installing pile
to prescribed depth3

9.Fixing of Skiplock Attachment
onto installed pile

10.Pitching of Driving Attachment
onto Skiplock Attachment
Driving Attachment

Driving Attachment

Clamps10.Pitching of Driving Attachment
onto Skiplock Attachment

11.eleasing of Clamps and raisingmachine body
12.Moving of machine body

Tubular Pile

11.eleasing of Clamps and raisingmachine body
12.Moving of machine body

14.Repeat 7-13 until completion (Removing
Reaction stand and reaction pile after
all clamp gripped Skiplock Attachment)
N.B.
Removing of Reaction Stand andreaction piles after Gyro Piler canoperate sololy on installed piles

4

13.Lowering of machine body andgripping Skiplock Attachment andReaction Stand

Chapter 3

Work Layout

3-1 Standard Operation (Above Ground)
Service Crane

Gyro Piler

Skiplock Attachments

Tubular PileGyro Piler

Power Unit
Driving Attachment

Water Lubrication System
Piling Direction

Power Unit

Driving Attachment

Service Crane

Tubular Pile

Plan View

Tubular Pile
Driving Attachment
Gyro Piler
Power Unit

Sectional View

5Service Crane3-2 Standard Operation (Above Water)

Tubular Pile

Gyro
GyroPiler
Piler

Piler Stage

Tubular Pile

Crane Barge
Power Unit

Piler Stage

Welding Machine
Generator

Tubular Pile

Plan View

Gyro Piler
Tubular Pile

Piler Stage

Sectional View

6

3-3 GRB Operation (Non-staging Method)

Rail for Pile Runner
Tubular Pile

Clamp Crane

Gyro Piler

Unit Runner

Piler Stage

Power Unit

Pile Runner

Piling Direction
Service Crane

Tubular Pile

Plan View
Clamp Crane
Pile Trackway
Tubular Pile

Gyro Piler
Pile RunnerUnit Runner

Sectional View

7

Power UnitPiler StageChapter 4

Machine Specification

4-1 Machine Specification F301-G1000
4-1-1 Gyro Piler
F301-G1000

SILENT PILER
Applicable sheet piles
Max. Press-in ForceMax. Extraction Force

Tubular Pile Ø600, 800, 1000 mm
with Chuck Rotation*

700 kN

without Chuck Rotation

800 kN

with Chuck Rotation*

850 kN

without Chuck Rotation

850 kN

Chuck Rotation Torque600kN・m

Chuck Rotation Velocity
StrokePress-in Speed
Extraction Speed

MAX 10.0 min850 mm
1.0 ~ 4.3 m/min
1.4 ~ 8.7 m/min

Applicable Pile Spacing
Control System-1

for 600mm

650 ~ 900 mm

for 800mm

850 ~ 1200 mm

for 1000mm

1050 ~ 1270 mm

Radio Control

Massfor 800mm

16000 kg

for 1000mm

16600 kg

17200 kg
for 1200mm* An external power source is required for Chuck rotation( 200V - 50/60 Hz, 220V - 60Hz, Min. 30KVA, 3 phases )4-1-2 Power Unit EU 300J4

Power Unit
Power Source
Rated Output

Diesel Engine
Power Mode

237 kW (322 ps) / 1800 min-1

Eco Mode

211 kW (287 ps) / 1600 min-1

Super Eco Mode8184 kW (250 ps) / 1400 min-1

Fuel Tank Capacity

500 L

Hydraulic Reservoir

Piler Eco Oil 490 L

Urea Additive Tank Capacity

38 L

Moving Speed
Mass

1.4 km / h
6500 kg (with 20m Hose)

4-1-3 Water Lubrication System OP114A
Lubrication System
Input Voltage (3 phases)
Water Pump Discharge Rate
Water Pump Discharge Pressure
Outer Tank Capacity (W×D×H)

Water Tank Capacity
Mass (without water)

OP114A
AC200V, 50 / 60 Hz, 24 KVA or more

Max. 60 L / minMax. 6 MPa
1505 × 755 × 1230 mm
300 L
410 kg*The above specifications are subject to alteration without prior notice.

SwivelWater Hose
Water Pipe
Generator
Tap Water

Submerged Pump
Water Outlet(Inside the tubuler pile)*Water Supply by Tap Water or Submerged Pump

94-1-4 Driving Attachment
Driving Attachment AM81
D600mm Form

Driving Attachment
Mass

AM81
1100 kg

Driving Attachment
MassAM69A
2000 kg

Driving Attachment AM69A
D800mm Form

Driving Attachment AM105
D1000mm Form

Driving Attachment
Mass

10AM105
3300 kg (D1000mm Form)
4500 kg (D1200mm Form)

4-1-5 Skiplock attachment
Tubular Pile

Gyro Piler

Driving Attachmentr

Skiplock Attachments

Skiplock Attachment AM162

Skiplock Attachment AM153

11Skiplock Attachment AM163

4-1-6 Reaction StandSheet Pile

Bolt Hole φ 24

Sheet Pile12

4-2 Machine Specification F401-G1200
4-2-1 Gyro Piler
F401-G1200

SILENT PILER
Applicable sheet piles
Max. Press-in ForceMax. Extraction Force
Chuck Rotation Torque
Chuck Rotation Velocity
StrokePress-in Speed
Extraction Speed
Applicable Pile Spacing
Control System
Mass

Tubular Pile Ø800, 1000, 1200 mm
1

Tubular Sheet Pile Ø800, 1000 mm*
with Chuck Rotation*
1500 kN
without Chuck Rotation

2000 kN

with Chuck Rotation*

1600 kN

without Chuck Rotation

2200 kN

900kN・m(Emergency use up to 1050kN・m)-1

MAX 10.0 min
1000 mm
0.7 ~ 4.9 m/min
0.7 ~ 3.5 m/min
for 800mm

850 ~ 1320 mm

for 1000mm

1050 ~ 1320 mm

for 1200mm

1250 ~ 1505 mm

Radio Control
for 800mm

31850 kg

for 1000mm

32600 kg

33600 kg
for 1200mm* An external power source is required for Chuck rotation( 200V - 50/60 Hz, 220V - 60Hz, Min. 30KVA, 3 phases )4-2-2 Piler Stage ST48

Saddle Stage

Piler Stage
Load Capacity

Leader Mast Stage
Saddle Stage

Stroke 900

Stroke 900

Leader Mast Stage

-18-13MassST48
550 kg (When set both sides)
300 kg (When set one side only)
300 kg2035 kg

4-2-3 Power Unit EU 500C3Power Unit
Power Source
Rated
OutputPower Mode
Eco ModeSuper Eco Mode

Fuel Tank Capacity
Hydraulic Reservoir
Moving Speed
Mass

EU500C3Diesel Engine-1
377 kW ( 513 ps) / 1800 min-1
335 kW ( 456 ps) / 1600 min-1
293 kW ( 399 ps) / 1400 min
850 L
Piler ECO Oil 660 L
1.4 km/h
10950 kg (with 30m Hose)

4-2-4 Water Lubrication System OP114ALubrication SystemOP114A

Input Voltage (3 phases)

AC200V, 50 / 60 Hz, 24 KVA or more

Water Pump Discharge Rate

Max. 60 L / minMax. 6 MPa
1505 × 755 × 1230 mm300 L
410 kgWater Pump Discharge Pressure

Outer Tank Capacity (W×D×H)
Water Tank Capacity
Mass (without water)*The above specifications are subject to alteration without prior notice.

SwivelWater Hose
Water Pipe
Generator
Tap Water

Submerged Pump
Water Outlet(Inside the tubuler pile)*Water Supply by Tap Water or Submerged Pump14

4-2-5 Driving Attachment
Driving Attachment AM69A
D800mm Form

Driving Attachment
MassAM69A
2000 kg

Driving Attachment
MassAM105
3300 kg (D1000mm Form)

Driving Attachment AM105
D1000mm Form

D1200mm FormDriving Attachment
AM105
Mass
4500 kg (D1200mm Form)

15

4-2-6 Skiplock attachment
Tubular Pile

Driving Attachment

Gyro Pilerr

Skiplock Attachments

Skiplock Attachment AM153

Skiplock Attachment AM163

16

Skiplock Attachment AM157

4-2-7 Reaction Stand

Bolt Hole φ 24

Sheet Pile

Construction Solutions Company

Sheet Pile

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Ver1.0EN01 / 16 Mar 2017